Contents Geniox VOClean Ecology Units User Manual
1 Detailed table of contents on the following pages General Descriptions A B C D E F Manufacturer Name of Machines Declaration of Conformity General Descriptions, Dangers and Warnings Drawings, Diagrams, Guides and Instructions for the Use, Maintenance and Repair Employees in Charge of Operation/Control/Maintenance Installation G Ecology Unit in Operation H Instruction for Unloading on the Site as well as Installation and Connection Start-up, Adjustments and Operation K Start-up, Adjustments, Use, Commis
2 Table List Table List Table 1. Table 2. Table 3. Table 4. Table 5. Cabinet Label Handling Methods ESP Technical Specifications Technical specifications of the Autowash system Technical Specifications of Odor Neutralizer Figure List Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25.
Contents Contents A B C D Manufacturer.......................................................................................................................................................... Name of machines............................................................................................................................................................. Declaration of Conformity - Example............................................................................................................
4 Contents Contents K.3.2 Speed control of fans.............................................................................................................................. K.3.3 Cabinet...................................................................................................................................................... K.3.4 Damper motors........................................................................................................................................ K.3.
Manufacturer 5 A Manufacturer This User Manual covers all ecology units delivered by Systemair Turkey. Contents Manufacturer and supplier data: Systemair Turkey Makina Organize Sanayi Bölgesi 41455Demirciler OSB Dilovası / Kocaeli Responsible for documentation: Ozge Sengoz B Name of machines This manual is about Systemair Ecology Units called Geniox VOClean 07.07, Geniox VOClean 11.07, Geniox VOClean 15.08, Geniox VOClean 11.13, Geniox VOClean 16.13, Geniox VOClean 20.13, Geniox VOClean 16.
6 Declaration of Conformity C Declaration of Conformity - Example The manufacturer: Systemair Turkey 41455 Demirciler OSB Dilovası / Kocaeli Hereby declares that, Ecology Units of the following types: Geniox VOClean 07.07, Geniox VOClean 11.07, Geniox VOClean 15.08, Geniox VOClean 11.13, Geniox VOClean 16.13, Geniox VOClean 20.13, Geniox VOClean 16.19, Geniox VOClean 20.19, Geniox VOClean 25.
General Descriptions, Dangers and Warnings 7 D General descriptions, dangers and warnings Geniox VOClean Ecology Units are intended for the transport and treatment of air between -40 °C and + 40 °C. The units are exclusively for kitchen exhaust filtration systems. Maintenance of the units must be carried out by skilled technicians. Contents D.1 Overview via pictograms on the inspection side of the unit 1 2 3 4 5 6 7 14 13 8 12 11 10 9 Figure 1. Pictograms on Unit D.1.
8 General Descriptions, Dangers and Warnings Position Description 7 Damper 8 Machine card 9 Branding 10 The Section Where Crane Lifting is Prohibited 11 Crane Lifting Section 12 Grounding 13 ESP Warning 14 Electrostatic Precipitator Warning about crushing Connect sections with identical numbers UVV Silencer Control (Automation) Panel Symbol
General Descriptions, Dangers and Warnings 9 D.1.2 CE label - example for the Geniox Ecology unit CE marking is printed on the machine card. Figure 2. Labelling D.2 Data about the unit according to cards and labels in and on the unit D.2.1 Example of Machine card with unique data on every unit The unique production number for the complete unit in this example is 1911-0005xxxxxx-10 where 19 indicates production year 2019 and 11 indicates production month at the Systemair factory in Turkey.
10 Drawings, diagrams, guides and instructions for the use, maintenance and repair E Drawings, diagrams, guides and instructions for the use, maintenance and repair All units are manufactured in compliance with the EC Declaration of Conformity and they are CE marked as machines. If the buyer carries out changes or adds components in or on the machine, the buyer must issue a new EC Declaration of Conformity and a new CE marking of the machine.
Instructions for Unloading the Site H.1.2 11 Unloading by fork-lift truck The forks of the truck must be sufficiently long to avoid any damage to the AHU underside. Figure 3. Unloading by Fork-lift H.1.3 Unloading by crane AHU delivered on transport pallet must be lifted by straps as shown in the illustration. Figure 4. Bracket H.1.4 Figure 5.
12 Instructions for Unloading the Site H.1.6 Lifting a unit with installed brackets on the base frame for lifting Figure 6 . Lifting from Base Frame Lifting beam and straps are not included in the delivery. The information about the weight of a section is very accurate and you must always be sure that the equipment intended for lifting the section is constructed and authorized for the task. H.1.
Instructions for Unloading the Site 13 Contents Do not activate the wheels of forklift on the horizontal profile of a middle profile. Activation of the wheels on the horizontal profile might bend the profile. The forks of the forklift must be longer than the width or length of the section/unit to achieve safe transport of the section/unit. Very important to check that the wheels of the forklift are never activated on the horizontal profile of the base frame on the other side of the section/unit.
14 Instructions for Unloading the Site H.1.9 Roof unit with PVC Avoid damaging the drip nose profiles along the PVC. Keep the protection profiles of Styrofoam on the unit until the installation has been completed. If the unit is lifted by straps, the straps must be kept away from the drip nose profiles by bars to avoid damage to roofing profiles. Figure 8. PVC Roof H.1.10 Pre-assembly storage The Ecology uint must be protected from the weather and accidental impact.
Installation H.2.3 15 Base frame assembly Base frame is delivered unassembled for the indoor units that are delivered in sections on pallets. Assembly of the base frame is illustrated on 4 pages in a manual in a plastic bag which is attached to one of the large base frame parts. There are two types of base frames: 1.118 mm high base frames 2.218 mm high base frames H.2.
16 Installation Note! Never - place the strap on the vertical profile when a section is pulled along the base frame or on the floor. Figure 11. Lifting with Rope from Base Warning Note! Place the strap on the bottom profiles of the unit to avoid any load and stress on the vertical profiles when sections are pulled together along the base frame or on the floor. The sections must be pulled fully and tight together with the strap placed on the bottom profiles.
Installation The sections are then to be positioned directly opposite each other. If the sections are built with legs, the adjust¬able feet can be used to get the sections in line and at the same height. Press the sections hard together so that the rubber pro¬files are so flat that the iron frames of the two sections are joined. Strap with tensioner is suitable for pressing the sections hard together.. Note! Do not place the strap on the vertical profiles.
18 Installation Assembly has been completed successfully The grey guiding and connection blocks might be installed inside the units on the vertical profiles. Press the sections hard together so that the rubber profiles are so flat that the iron frames of the two sections are joined. Strap with tensioner is suitable for pressing the sections hard together. Note! Do not place the strap on the vertical profiles.
Installation H.2.6 19 Remove transport brackets - when spring mounts are installed If the fans are installed on spring mounts the transport brackets must be removed after the installation of the air handling unit. Two transport brackets are fitted to the coil springs during transport and installation. Both transport brackets must all be removed to give the full anti-vibration function to the coil springs. The transport brackets are made more visible with yellow labels.
20 Installation H.2.10 Installation of the EPA/HEPA Filter Rails have been mounted within the section to enable installation of the EPA and HEPA filters. The EPA and HEPA filters should be slid in a vertical position on these rails within the section, as shown in “Figure 17”. Figure 17: Installation of EPA/HEPA and Bag Filters Figure 18: The appearance of EPA/HEPA and bag filters after filter installation H.2.
Installation 21 H.2.12 Installation of ESP Collector While placing ESP collectors inside the ecology unit, care should be taken to ensure that the section where the ionizer wires are located face the direction of air intake. Collectors placed consecutively must be in contact with each other. The electricity-conducting section at the ESP door must be in contact with the section on the collector that receives the electrical current. Figure 21: Installation of ESP collectors H.2.13.
22 Installation H.2.14 Installation of the Autowash System Water that comes into the Autowash system panel is split into branches inside the panel and each branch sends water to each wash groups of the autowash system separately. Once the water pipes located here have been connected, clamps should be used to prevent the pressure inside the pipe from dislodging the hoses.
Start-Up K.2.1 23 Checklist, relevant values K.2.1.1 Checklist prior to start-up • • • • • • • Is the unit assembled correctly with its functions in the correct order? Are the sections and ducts assembled correct? Check that fans and anti-vibration mounts are not damaged after transportation and installation.
24 Start-Up K.3.4 Damper motors On/off damper motor, without spring return function. Torque is 5-20 Nm and run time is 150 seconds. For units not equipped with damper motors, damper blades should be opened with the help of the damper shaft rotating lever before starting the unit. In automated models, no manual intervention should be made on the damper.
Start-Up 25 K.3.8 Autowash System 230V, 50Hz electrical supply should be connected to the unit for the Autowash system to operate. Once the water pipes have been installed as instructed in the assembly section, the valve for the water that will be supplied to the Autowash system should be opened. The water pressure should be read from the manometer shown in “Figure 24” and the read pressure value should be around 2 bar. Note: Maximum permissible pressure is 7 bar.
26 Start-Up Afterwards, the lock below this lamp should be opened using its dedicated key in order for the “ESP Enable” lamp (green) to come on. Figure 26: ESP activator lock and key If the blue alarm lamp seen on “Figure 27” is on, this means that either the water pressure is too low, or the water valve has not been opened, or there isn’t enough detergent in the detergent tank. The reason for this light being on can be read from the PLC display as seen in “Figure 28”.
Start-Up 27 Then, the blue “Alarm Reset” button seen on “Figure 29” should be pressed. Anytime this button is pressed, the red “Stop/Reset” button seen in “Figure 40” should be pressed subsequently. When the alarm reset button is pressed Figure 29: The alarm reset procedure and the text displayed on the PLC screen Figure 30: The Stop/Reset Button The “Start” button located to the left of PLC as seen in “Figure 31” should be pressed to start the wash cycle.
28 Start-Up After the allotted time has elapsed, the ecology unit comes back online. Each wash cycle is completed in a set period and these periods can be reprogrammed if wanted. To do this, press the “ESC” button on the PLC. You can change the sections you want by using the “Parameters” and “Clock” menus from the displayed menu. The procedure for making these changes is shown in “Figure 32”. Reprogramming is not recommended. Figure 32: Reprogramming the washing period over PLC K.3.
Start-Up 29 K.3.10 Odor Neutralizing Unit During initial installation of the odor neutralizing unit, care should be taken to ensure that the angular section of pipe which extends into the ecology. If the angular section of the pipe is facing another direction, the pipe should be rotated so it faces the right one. Otherwise the air inside the air handling unit will enter the pipe and hinder the function of the odor neutralizing unit.
30 Information About the Residual Risks The quantity of odor neutralizing agent vapor that comes out of the odor neutralizing unit can be adjusted using the vapor control damper seen in “Figure 35”.
Information About the Residual Risks L.1.2 31 Common for all unit sections L.1.2.1 Risk caused by surfaces, edges and corners Hazards/dangerous area: • Sharp edges on plates might occur inside the machines as well as sharp edges on frames of dampers. No sharp edges on the outside of the units. Hazards/dangerous area: • Sharp edges on plates might occur inside the machines as well as sharp edges on frames of dampers. No sharp edges on the outside of the units.
32 Information About the Residual Risks L.1.2.4 Risk caused by missing change of filters Hazards/dangerous area: • Missing change of filters and missing maintenance decrease the capacity and final consequence will be breakdown. Dangerous incident: • By extensive lack of of filter change and maintenance the machine can break down. Claim for reduction of danger: • In the manual is the method and schedule for change of filters and maintenance specified. L.1.2.
Recommended Maintenance Interval 33 N.2 General disassembly - sharp edges Pay attention to several sharp edges during dismantling and disposal of the unit. To avoid injury, CE-marked cut-resist¬ant gloves as well as helmet must be used. The measures are described further in the Maintenance, Dismantling and Disposal Manual.
34 Recommended Maintenance Interval R.2. Filters Region Max. Differential Pressure (Pa) Instructions The cleaning period of metallic filters will change according to intensity of use and the type of cuisine. Therefore it is recommended that maintenance and cleaning be performed at intervals determined according to to intensity of use and the type of cuisine. Remove panel filters by sliding them toward yourself. If there are tears or pores in filters, replace them.
Recommended Maintenance Interval 35 R.3. Autowash System Region Interval Instructions Contents Checks should be performed on regular intervals to make sure that the pipes used in the Autowash system have not been dislodged and that there are no holes in pipes. Water Pipes Of The Autowash System 1-2 Weeks If the pipes have been dislodged, they should be fixed in place and well tightened using clamps.
36 Recommended Maintenance Interval R.4. ESP (Electrostatic Filter) Region Interval ESP Pan 1 Week -3 Months Instructions Remove the ESP pan by sliding it toward yourself. Clean the oil residue inside the pan at specified periods, using a cloth and mixture of water at 50-60°C and degreasing detergent. Make sure the pan is dry before replacing it. Remove the ESP collectors by sliding them toward yourself.
Recommended Maintenance Interval 37 INFORMATION Contents Once you have completed the maintenance and cleaning procedures and started the ESP device, crackling or arcing sounds can be heard initially as the system begins to load. This is completely normal. WARNING If the crackling and arcing sounds continue and if the green” in operation” lamp comes off, this means there is a problem with the device. In this case cut the electrical supply to the unit and alert service teams.
38 Recommended Maintenance Interval R.6. Odor Neutralizing Unit Region Interval Odor Neutralizing Agent Level Indicator 2-4 Weeks Instructions The odor neutralizing agent level varies according to the flow rate of exhausted air and the amount of odor contained in the exhaust air. On average use, 1 liter of odor neutralizing agent can last 3-4 weeks. The quantity of odor neutralizing agent should be checked at specified intervals and topped off as necessary.
Recommended Maintenance Interval 39 R.8. Dampers Region Interval Instructions Contents If a unit with damper motors is used rotate the shaft by pressing the button or if there is no damper motor, rotate the shaft manually using the shaft lever. Check for any jamming in the blades. If there is dust, gravel etc. at the edges of blades which hinder the easy movement of blades, clean with a brush or cloth. Clean the dust accumulated on the surfaces of blades with a moist, clean cloth.
40 Troubleshooting R.10. Troubleshooting Malfunction Possible Cause Solution The ESP cam switch may not be on or the on-off button may not have been pressed. Check the cam switch or the on-off button and if they are in the off position switch to the on position/press the button. Carry out the procedure described in the maintenance and cleaning section regarding ESP. Exhaust air is greasy and smoky. If there is an Autowash System, it may be offline.
Troubleshooting Malfunction Air flow rate in the unit is too low. The unit’s operation is noisy. Crackling and arcing sounds are coming from the device. Unit is not working. 41 Contents Possible Cause Solution The frequency at the potentiometer or inverter may be at a low level. Increase the rotational speed of the fan by rotating the potentiometer in the positive direction or by increasing frequency from the inverter. Filters may have been filled with dirt and be causing additional pressure.
42 Components and Technical Specifications S Components and Technical Specifications The Geniox VOClean Ecology Unit is tasked with cleaning the greasy, foul smelling, dirty, smoky exhaust air from industrial kitchens. Various components are used to perform this function. These components have been explained in detail below. S.1 Electrostatic Filter (ESP) The electrostatic filter is made up of two main parts.
Components and Technical Specifications 43 Technical specifications of the ESP used in the Geniox VOClean Ecology Unit are shown in “Table 3” and the panel is shown in “Figure 39”. ESP 1500 Technical Specifications Power Consumption 20 Watts Maximum Capacity 0,7m³/s Power Supply 1” / 220-240V / 50 Hz Filter Efficiency %98 Table 3: ESP Technical Specifications Operating Status LED Indicator Cam Switch Label Panel Door Figure 39: ESP Panel S.
44 Components and Technical Specifications Washing Nozzles Water Supply Hose Figure 40: Panel and washing group of the Autowash system “Table 4” shows the electrical specifications of the autowash system. Mains Power Supply for the Autowash System 230V-50Hz-6Amp Power 35W Table 4: Technical specifications of the Autowash system S.3 UV-V Lamp UV-V lamps are used in ecology units to destroy grease and odor particles. UV-V lamps emit ultraviolet light at a wavelength of 185 nm.
Components and Technical Specifications 45 “Figure 41” shows a UV-V lamp connected to a power source (ballast). Contents Figure 41: UV-V lamp connected to ballast S.4. Bag Filter Bag filters of various classes (F7, F8, F9) are used as optional material in the Geniox VOClean Ecology Unit.
46 Components and Technical Specifications S.7 Active Carbon Filter Active carbon filters comprising cartridges having an external diameter of 140 mm, thickness of 70 mm, and length of 600 mm are used in Geniox VOClean Ecology Units. Active carbon material has extremely small pores in its structure. The total surface area of these pores is quite high.
Components and Technical Specifications 47 Contents Vapor Control Damper Fan Speed Control Adjustment Button High Voltage Power Supply Tank Fill Opening Cover Tank Fill Opening Fast Opening Locks Level Indicator Figure 44: Components inside the casing of the odor neutralizing unit “Table 5” shows the technical specifications of the odor neutralizing unit.
48 Components and Technical Specifications S.10. Silencer Silencers used in Geniox VOClean Ecology Units are composed of rock wool and glass wool. Each silencer coulisse with a thickness of 200 mm can be manufactured and used in varying lengths. The polluted kitchen exhaust air enters the Geniox VOClean Ecology Unit and is scrubbed clean by the unit and discharged as clean air. Silencers are installed at the discharge sites of ecology units to keep them clean. Figure 45: Silencer S.11.
Components and Technical Specifications 49 S.12. Potentiometer (MTP10) Systemair potentiometers which are supplied as an option vary voltage output by altering the resistance in the electrical circuit. When a change is made in the potentiometer, the frequency inverter is initialized to bring the static pressure above or below the static pressure measured in the pressure differential transmitter, changing the fan speed.
50 Components and Technical Specifications S.15. Door Switch Door switches are used for various purposes in Geniox VOClean Ecology Units. One of these purposes is to cut the electrical supply to the fan when the door of a fan section is opened; and another is to cut the electrical supply to the UV-V lamp when the door to any section is opened, if there is a UV-V lamp in use. A visual representation of the door switch that is used can be seen in “Figure 50”.
Notes Notes 51
52 Notes Notes
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